Helmet having interior ventilation channels

ABSTRACT

In accordance with the teachings of the present invention, a helmet having interior ventilation channels is provided. In a particular embodiment, the helmet includes at least one protective layer configured to cover at least a portion of a user&#39;s head and a plurality of pads coupled to the protective layer, the pads defining a network of interconnected ventilation channels between the pads, the ventilation channels substantially covering an interior of the protective layer and allowing air circulation between the protective layer and the user&#39;s head when the helmet is worn by the user.

TECHNICAL FIELD OF THE INVENTION

The present invention relates generally to protective headgear and, moreparticularly, to a helmet having interior ventilation channels.

BACKGROUND

Protective headgear, such as helmets, are often used in activities, suchas bicycling, skateboarding, motorcycling, race car driving, rockclimbing, snowboarding, and skiing, that are associated with anincreased risk of head injury. Typically, such protective headgear isdesigned to maintain its structural integrity and stay secured to thehead of a wearer, while protecting the wearer from a trauma to the head.In many types of protective headgear, such as motorcycle helmets, it isoften desirable to offer substantially full coverage to the top, back,and sides of the wearer's head to better protect the wearer from headtraumas. Unfortunately, this full coverage may also cause heat andperspiration to accumulate within the interior of the helmet leading touser discomfort.

SUMMARY

In accordance with the teachings of the present invention, a helmethaving interior ventilation channels is provided. In a particularembodiment, the helmet includes at least one protective layer configuredto cover at least a portion of a user's head and a plurality of padscoupled to the protective layer, the pads defining a network ofinterconnected ventilation channels between the pads, the ventilationchannels substantially covering an interior of the protective layer andallowing air circulation between the protective layer and the user'shead when the helmet is worn by the user.

Technical advantages of one or more embodiments of the present inventionmay include providing for increased circulation of air within a helmetto dissipate heat within the helmet. The dissipation of heat mayincrease user comfort. Such heat dissipation is provided by ventilationchannels surrounding a user's head that allow air to flow from outsideof the helmet, over the user's head, and out of the helmet. Theventilation channels are formed by pads.

Another technical advantage of particular embodiments of the presentinvention includes providing a helmet with a more comfortable fitagainst a user's head. The pads in particular embodiments allow for amore personalized fit for each individual. For example, the pads ofparticular embodiments may more comfortably accommodate different headshapes of different users by yielding to a user's head more easily.

It will be understood that the various embodiments of the presentinvention may include some, all, or none of the enumerated technicaladvantages. In addition, other technical advantages of the presentinvention may be readily apparent to one skilled in the art from thefigures, description and claims included herein.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the present invention and itsfeatures and advantages, reference is now made to the followingdescription, taken in conjunction with the accompanying drawings, inwhich:

FIG. 1 is a diagram illustrating a side view (with portions broken away)of a helmet according to one embodiment of the present invention;

FIG. 2 is a diagram illustrating a bottom view of the helmet of FIG. 1;and

FIG. 3 is a flowchart of an example method of manufacturing the helmetof FIGS. 1 and 2 according to one embodiment of the present invention.

DETAILED DESCRIPTION

FIGS. 1 and 2 illustrate an example helmet 10 operable to protect auser's (a wearer's) head 20. FIG. 1 is a diagram illustrating a sideview (with portions broken away) of a helmet according to one embodimentof the present invention. FIG. 2 is a diagram illustrating a bottom viewof the helmet of FIG. 1.

Example helmet 10 may offer coverage to any one or more parts of theuser's head, including, for example, the top, back, and sides of theuser's head, to protect the user from head traumas. Although helmet 10is a motorcycle helmet, helmets made according to the present inventionmay include any type of protective headgear, including, for example andwithout limitation, a bicycling, skateboarding, motorcycling, race cardriving, rock climbing, snowboarding, and skiing helmet. Helmet 10comprises an inner protective layer 30, an outer protective layer 40,vents 50 and 60, ventilation channels 70, and pads 80.

Inner protective layer 30 includes any layer of material or combinationof materials operable to protect a user's head from an impact, such as,for example, expanded polystyrene (EPS). Outer protective layer (orshell) 40 includes any layer of material or combination of materialsoperable to provide an additional layer of protection around innerprotective layer 30, such as, for example and without limitation,polycarbonate plastic, carbon fiber/Kevlar/fiberglass tri-weave, orfiberglass. As illustrated in the example embodiment in FIGS. 1 and 2,inner protective layer 30 of helmet 10 may be disposed substantiallywithin outer protective layer 40. However, inner protective layer 30 maynot be covered by protective layer 40 in certain locations. In addition,although two protective layers 30 and 40 are illustrated in the exampleembodiment, there may only be one protective layer or there may be morethan two protective layers in other embodiments.

As described above, helmets are used in a variety of activities, suchas, for example, bicycling, skateboarding, motorcycling, race cardriving, rock climbing, snowboarding, and skiing. Helmets offersubstantially full coverage to the top, back, and sides of the user'shead to better protect the user from head traumas. As a disadvantageousby-product, the helmet's substantially full coverage of the user's headgenerates heat within the interior of the helmet, leading to userdiscomfort.

To alleviate the discomfort from heat generated within the helmet, usersmay require some form of ventilation. Helmets may include vents or otherair intake or outtake devices to introduce air into the helmet and toallow air to leave the helmet. Users may also lift the protective faceshield (if one is provided) to an open position to admit air.

In the illustrated embodiment, ventilation is provided by air vents 50and 60. Air vents (or ports) 50 and 60 include any vent or combinationof vents operable to allow air to enter or leave the inside of thehelmet 10. Although air intake vents 50 are located in the examplehelmet 10 in a position corresponding to the user's forehead and mouth,vents 50 may be positioned anywhere on helmet 10, including, forexample, the sides and/or top of helmet 10. Additionally, exhaust vents60, although located at the back of helmet 10, may also be positionedanywhere on helmet 10, including, for example, the sides of helmet 10.In addition, though vents 50 and 60 are illustrated in the exampleembodiment as being separate, they may be combined into one vent thatallows air to both enter and leave helmet 10. Ventilation may also beachieved through other means and may not even require any vents 50 or 60at all. For example, air may enter and/or exit the helmet around theface shield of the helmet or around the user's neck.

As many users of prior helmet designs have found, however, ventilationby air vents alone often does not alleviate the discomfort due to heatgenerated within the helmet. The reason that vents alone do notalleviate the discomfort from heat generation is that the ventilated airdoes not adequately travel within the interior of the helmet to cool theuser's head. Prior helmets have not been designed to provide foradequate circulation of air within the helmet. Prior helmets have soughtto cool the user using multiple vents and breathable liners, but thesehelmets have inadequately allowed air to circulate within the helmet.Although particular prior helmets have comprised limited “channels”between large pads, these “channels” have not been designed to providecirculation of air around much of the user's head, being too few innumber and too narrow and shallow to be effective.

Referring back to FIGS. 1 and 2, example helmet 10 provides a network ofinterconnecting ventilation channels 70 around the user's head 20 toallow for increased circulation of air within helmet 10. Ventilationchannels 70 are defined by pads 80 located in example helmet 10 betweenthe inner protective layer 30 and the user's head 20. Pads 80 arepositioned around the interior of the helmet to form, in the illustratedembodiment, a network of interconnected ventilation channels 70 thatsubstantially surrounds the user's head. This allows air coming into thehelmet to easily circulate around much of the user's head and thus tocool the user's head. Thus, compared to previous helmets having few, ifany, spaces between the helmet pads, helmet 10 provides vastly increasedair circulation. Furthermore, because less of the helmet 10 is incontact with the user's head, the fit for the user is more comfortable.

Pads 80 may comprise one or more materials with differing densities,consistencies, or other properties. In particular embodiments, one ormore pads 80 may comprise a foam material, such as, for example, closedcell foam or open cell foam. One example of closed cell foam that may beused is CONFOR® CF-45 foam. In particular embodiments, as an example,pads 80 may comprise closed cell foam with a density greater than theopen cell foam used in typical helmet pads (which may have, as anexample, a density of two to three pounds per cubic feet). In particularembodiments, as an example only, the density of pads 80 may compriseapproximately six pounds per cubic feet. The density of the materialcomprising pads 80 may also differ. For example, the density of the foamcomprising pads 80 in some embodiments may vary along a gradient fromlow to high density foam. The material comprising pads 80 need not beuniform in some embodiments and may include air pockets, other closed oropen chambers, and/or holes. In addition, all pads 80 in one helmet 10need not comprise the same material. For example and without limitation,one or more pads may comprise a first material, another pad or pads maycomprise a second material, yet another pad or pads may comprise a thirdmaterial, and so on.

Pads 80 may also comprise a liner material 82 surrounding part or all oftheir surface area to reduce friction between the pads and a user's headand/or to generally provide comfort to the user. For example, asillustrated in helmet 10 of FIGS. 1 and 2, liner material 82 may coverthe surface area on the end of the pads 80 that contacts the user's head20. In some embodiments, liner material 82 may include Lycra or someother form of spandex. Other suitable materials may alternatively beused. Liner material 82 may provide for increased comfort during use andmay allow a user to put the helmet 10 on and take the helmet 10 off withgreater ease and reduced stress on the pads 80.

Pads 80 in example helmet 10 are illustrated as being cylindrical withcircular cross-sections oriented to face the user's head 20. However,pads 80 may be any shape or any combination of shapes, and may beoriented in any manner. For example, pads 80 may comprise cylindershaving non-circular cross-sections, such as an oval cross-section or apolygonal cross-section. Pads 80 may also include, for example, cones,pyramids, wedges, hemispheres or any other suitable shape or combinationof shapes. In particular embodiments, the shape of pads 80 may be chosento increase airflow through channels 70 and may even be shaped to directthe airflow flowing around a pad 80 in a certain direction (for example,using a “tear drop” cross-section oriented in a particular direction).

In one or more embodiments, pads 80 may all be one size, or pads 80 maybe various sizes, such as, for example, in helmet 10 of FIGS. 1 and 2.Pads 80 may be the same or different heights, lengths, or widths, orhave the same or different surface areas or volumes. For example, incertain embodiments, pads 80 may have a height of approximately twentymillimeters. In other embodiments, the height of pads 80 may be greateror lesser than this amount. Pads 80 may all be in contact with user'shead 20 when the user is wearing helmet 10, or some may and others maynot be in contact with user's head 20, depending on the size and shapeof the head.

The example helmet 10 of FIGS. 1 and 2 includes approximately sixty pads80. However, helmets according to embodiments of the present inventionmay comprise any number of pads suitable to create a network ofinterconnecting ventilation channels 70 around the user's head 20 toallow for increased circulation of air within helmet 10. Thus, otherembodiments may include less or more pads than in example helmet 10 ofFIGS. 1 and 2. According to particular embodiments, as an example, fortyor more pads 80 may be used for a full face helmet to provide increasedventilation of a user's head. In addition or alternatively, inparticular embodiments, pads 80 may occupy thirty percent or less of thesurface area of the interior of the protective layer. In particularembodiments, as an example, pads 80 may have an area to height ratio (avolume distribution) less than the fifty to one ratio of many typicalpads. In certain embodiments, and as an example, the ratio of area toheight may be approximately one to one. It should be noted that “pads,”as used herein, may refer to separate pads and/or to padded extensionsextending from one pad that provides a common backing for the paddedextensions. Thus, references to a “plurality of pads” or to some numberof pads may refer to a plurality or some number of separate pads,respectively, and/or to a plurality or some number of padded extensions,respectively, extending from one pad that provides a common backing forthe padded extensions.

As in example helmet 10 of FIGS. 1 and 2, the spacing between adjacentpads may be variable. In other embodiments, the spacing between adjacentpads may be constant or be different than that in example helmet 10. Thespacing between pads 80 may comprise any variation suitable to create anetwork of interconnecting ventilation channels 70 around the user'shead 20 to allow for increased circulation of air within helmet 10. Inparticular embodiments, as an example, adjacent pads may be spaced apartsix or more millimeters to provide for increased circulation.

Pads 80 may be attached to inner protective layer 30 using an adhesive.Alternatively, pads 80 may be secured inside the inner protective layerusing any other suitable method of coupling the pads 80 to theprotective layer 30 (and/or the shell 40).

In operation, according to one embodiment, air 90 from outside of helmet10 enters helmet 10 through vents 50 (and possibly through otherlocations). Vents 50 direct the air 90 into the interior of the helmet10. More specifically, vents 50 direct the air 90 into the ventilationchannels 70 between layer 30 and the user's head 20. The air 90 travelsthrough ventilation channels 70 in any direction, or in multipledirections, around pads 80. The air 90 thereby cools the user's head 20.The air 90 then exits through vents 60. Again, vents 50 and 60 may, insome embodiments, be the same vent or vents in one or more positions onthe helmet 10. By allowing air 90 to flow through ventilation channels70, helmet 10 allows the air 90 to cool the user's head 20, decreasingthe user's discomfort from the heat generated by wearing helmet 10.

Modifications, additions, or omissions may be made to the helmet 10described without departing from the scope of the invention. Thecomponents of the helmet 10 described may be integrated or separatedaccording to particular needs. Moreover, the operations of the helmet 10described may be performed by more, fewer, or other components.

FIG. 3 illustrates a flowchart 200 of an example method of manufacturingthe helmet 10 of FIGS. 1 and 2 according to one embodiment of thepresent invention. Flowchart 200 begins at step 202, where an innerprotective layer is formed from a suitable material that can protect auser's head from an impact. An example of one such material is expandedpolystyrene (EPS). Typically, this inner protective layer is formed byinjecting a mold in the shape of the inner protective layer with EPS andthen heating the mold such that the EPS expands to take the shape of themold. In particular embodiments, this inner protective layer may also beformed as separate parts which are later joined to form a single innerprotective layer.

At step 204, an outer protective shell is formed from a material thatcan provide an additional layer of protection around the innerprotective layer. Examples of such a material include carbonfiber/Kevlar/fiberglass tri-weave, fiberglass, and injection-moldedpolycarbonate plastic. In particular embodiments, this outer protectiveshell is formed separately from the inner protective shell.

At step 206, one or more vents may be formed through the innerprotective layer and/or the outer protective shell at one or morelocations. These vents provide a passageway through which airflow may bedirected into the interior of the inner protective layer to cool theuser's head. In particular embodiments of the present invention, thesevents may be formed at the same time as the inner protective layerand/or the outer protective shell. In such an embodiment, the vents maysimply be defined by the mold used to form the inner protective layerand/or the outer protective shell. In other embodiments, the vents maybe formed through the inner protective layer and/or the outer protectiveshell by machining or other suitable means.

At step 208, the inner protective layer is inserted into the outerprotective shell. In particular embodiments of the present invention,this may require inserting the inner protective layer into the outerprotective shell in separate pieces, as inner protective layer may betoo large to fit through the facial opening or neck opening of the outerprotective shell in one piece. Once inserted into the outer protectiveshell, the inner protective layer may be secured inside the outerprotective shell using an adhesive or other suitable method of couplingthe two.

At step 210, pads are formed from one or more materials with the same ordiffering densities, consistencies, or other properties. In one or moreembodiments, one or more pads may comprise a foam material. For example,one or more of the pads may comprise closed cell foam, such as, forexample, CONFOR® CF-45 foam. In another embodiment, one or more of thepads may comprise open cell foam. The density of the foam comprising thepads may also vary along a gradient from low to high density foam. Thematerial comprising the pads need not be uniform and may include airpockets, other closed or open chambers, and/or holes. Pads also need notcomprise the same material, so that, for example, some pads may compriseone material and others may comprise another material. The pads may beformed in any shape or combination of shapes, such as cylindrical shapeswith circular cross-sections. The pads may be formed to be approximatelythe same size or various sizes. They may be formed to be the same ordifferent heights, lengths, or widths, or have the same or differentsurface areas or volumes.

At step 212, a liner may be coupled to part or all of the surface areaof the pads to reduce friction between the pads and a user's head duringuse and/or to generally provide comfort to the user. The liner may beformed from any suitable liner material such as, for example, Lycra orsome other form of spandex. This liner material may allow a user to putthe helmet on and take the helmet off with greater ease and reducedstress on the pads. The liner may be secured to the pads using anadhesive, stitching, or any other suitable method of coupling the linerand the pads. It should be noted that the liner may be coupled to thepad material before individual pads are formed (at step 210). Inparticular embodiments, a liner may not be used.

At step 214, the pads are inserted into the inner protective layer. Thepads may be inserted in such a way as to be in contact with a user'shead when the user is wearing the helmet. Alternatively, they may beinserted such that some pads may and others may not be in contact withthe user's head when the user is wearing the helmet. The pads may beplaced in any position around the inner protective layer and in anyorientation, in a manner that allows suitable circulation of air througha network of interconnected ventilation channels that substantiallysurround a user's head during use. The pads may be secured inside theinner protective layer using an adhesive or other suitable method ofcoupling the pads and the layer and/or the shell.

Although flowchart 200 describes a particular order of steps forassembling a ventilated helmet in accordance with a particularembodiment of the present invention, particular embodiments of thepresent invention may use all, some, or none of the steps describedabove. Moreover, particular embodiments may perform those steps in adifferent order than that described above without departing from theteachings of the present invention.

By directing airflow from the exterior of a helmet into the interior ofa helmet and allowing for the air to circulate around a user's head,particular embodiments of the present invention offer improvedventilation for the user, helping to cool the user's head and dissipateheat. The dissipation of heat may increase user comfort. Anothertechnical advantage of particular embodiments of the present inventionincludes providing a helmet with a more comfortable fit against a user'shead.

Although the present invention has been described with severalembodiments, various changes and modifications may be suggested to oneskilled in the art. It is intended that the present invention encompasssuch changes and modifications as fall within the scope of the appendedclaims.

1. A helmet, comprising: at least one protective layer configured tocover at least a portion of a user's head; and a plurality of padscoupled to the protective layer, the pads defining a network ofinterconnected ventilation channels between the pads, the ventilationchannels substantially covering an interior of the protective layer andallowing air circulation between the protective layer and the user'shead when the helmet is worn by the user.
 2. The helmet of claim 1,wherein thirty percent or less of the surface area of the interior ofthe protective layer is covered by pads.
 3. The helmet of claim 1,wherein the at least one protective layer comprises: an outer protectiveshell; and an inner protective layer disposed substantially within theouter protective shell.
 4. The helmet of claim 1, further comprising atleast one port configured to allow air to flow from an exterior of thehelmet into an interior of the helmet.
 5. The helmet of claim 1, whereinthe plurality of pads comprise at least forty pads.
 6. The helmet ofclaim 1, wherein at least one of the plurality of pads comprises foam.7. The helmet of claim 6, wherein at least one of the plurality of padscomprises high-density, closed cell foam.
 8. The helmet of claim 1,further comprising a liner material covering at least a portion of oneor more of the pads.
 9. The helmet of claim 1, wherein the minimumdistance between any two adjacent pads comprises six millimeters. 10.The helmet of claim 1, wherein at least one of the plurality of padscomprises a cylindrical shape.
 11. The helmet of claim 10, wherein atleast one of the plurality of pads comprises a cylindrical shape havinga circular, oval, or polygonal cross-section.
 12. The helmet of claim 1,wherein at least one of the plurality of pads comprises an area toheight ratio of less than fifty to one.
 13. A method of manufacturing ahelmet, comprising: providing at least one protective layer configuredto cover at least a portion of a user's head; and coupling a pluralityof pads to the protective layer, the pads defining a network ofinterconnected ventilation channels between the pads, the ventilationchannels substantially covering an interior of the protective layer andallowing air circulation between the protective layer and the user'shead when the helmet is worn by the user.
 14. The method of claim 13,wherein thirty percent or less of the surface area of the interior ofthe protective layer is covered by pads.
 15. The method of claim 13,wherein the at least one protective layer comprises: an outer protectiveshell; and an inner protective layer disposed substantially within theouter protective shell.
 16. The method of claim 13, wherein the at leastone protective layer comprises at least one port configured to allow airto flow from an exterior of the helmet into an interior of the helmet.17. The method of claim 13, wherein the plurality of pads comprise atleast forty pads.
 18. The method of claim 13, wherein at least one ofthe plurality of pads comprises foam.
 19. The method of claim 18,wherein at least one of the plurality of pads comprises high-density,closed cell foam.
 20. The method of claim 13, further comprisingcoupling a liner material to one or more of the pads, such that theliner material covers at least a portion of one or more of the pads. 21.The method of claim 13, wherein the minimum distance between any twoadjacent pads comprises six millimeters.
 22. The method of claim 13,wherein at least one of the plurality of pads comprises a cylindricalshape.
 23. The method of claim 22, wherein at least one of the pluralityof pads comprises a cylindrical shape having a circular, oval, orpolygonal cross-section.
 24. The method of claim 13, wherein at leastone of the plurality of pads comprises an area to height ratio of lessthan fifty to one.